12 Tips for How to Improve Quality in Production

Production quality problems can potentially cost companies millions in scrap, rework, and warranty claims. In fact, a 2024 survey found recalls cost companies nearly $100 million. Even worse, they damage customer trust and delay product launches. Understanding how to improve quality in production starts with learning the importance of clear standards, smart process design, and team involvement at every stage.

This post walks through 12 practical steps to reduce defects, improve production efficiency, and build quality into your workflow. You’ll find specific techniques, tools, and best practices that bring measurable improvements without overcomplicating the process.

Why Quality in Production Matters

Quality in production shapes every downstream outcome for your product line. In Q1 2025 alone, U.S. regulators logged 101 consumer product recalls that forced companies to pull 4.64 million units from the market, along with more than $28 million in fines. Defects caught late cost more to fix than those spotted during early builds, and high scrap rates drain margins, slow cash flow, and delay shipments.

On the other hand, strong production quality reduces waste, speeds delivery, and builds customer confidence. Teams that control quality from the start face fewer fire drills and can focus on increasing production — instead of constant troubleshooting. 

Stable processes keep schedules predictable and make each build more consistent. That predictability simplifies forecasting and capacity planning and gives engineering and design space to focus on the next generation of products.

1. Define What “Quality” Means for This Product

Saying you want your product to be “high quality” isn’t specific enough. Quality must translate into measurable targets that designers, engineers, and operators can verify. Without clear definitions, every inspector and shift supervisor applies their own standards. 

Consider:

• Durability and lifetime in real use
• Cosmetic standards for surfaces, gaps, and color (e.g., lack of warp, consistent color, high-quality post-processing, high-yield tools, clean and smooth surfaces)
• Performance ranges for key functions
• Safety and compliance requirements

User experience factors, such as tactile feedback, actuation force, material feel, and hinge resistance, should sit alongside your other quality targets. Teams refine these details during design for manufacturing (DFM) with the factory, tuning how parts come together. That work is essential to a premium product experience and happens after the overall design intent is set.

2. Bring Manufacturing Into Design Reviews Early

Early involvement from manufacturing engineers and key suppliers prevents designs that are hard to build. Their input on process limits and tooling constraints reduces late engineering changes, failed pilot runs, and launch delays. You’ll spot problems on paper instead of on the production floor.

It’s important to keep in mind what’s achievable within the budget, minimum order quantity, and timeline. These factors can drive key decisions, such as adjusting the design or choosing a vendor better suited to meet the requirements. Aligning these constraints early keeps projects on track and avoids expensive surprises during ramp-up.

3. Map Your Production Flow and Spot Friction

Mapping the production flow from raw material to packed product reveals where defects and delays are likely to appear. Look for long travel distances, frequent handoffs, rework loops, and stations that always seem to be “in trouble.” These friction points create bottlenecks and quality issues.

Using flowcharts to visualize production and identify friction points is critical to timely product launches. Regular engagement from key stakeholders ensures the process stays aligned and potential bottlenecks are addressed proactively. Use that map to choose a few high-impact changes, such as:

• Moving stations
• Combining steps
• Adding a simple in-line check where issues tend to start

4. Use 5S to Create Clean, Predictable Workspaces

Utilizing 5S is a practical way to support quality by making tools, parts, and workflows consistent. These 5S’s help reduce errors, speed training, and make it easier to see abnormal conditions before they turn into defects.

• Sort: Remove everything from the workspace that isn’t needed for current production. Keep only the tools, materials, and documentation required for the job.
• Set in order: Arrange items so they’re easy to find and return. Label locations, use shadow boards for tools, and place frequently used items within arm’s reach.
• Shine: Clean equipment and workstations regularly to spot leaks, wear, and damage. A clean line makes it easier to see abnormal conditions before they cause defects.
• Standardize: Document the best method for each task and make it the default. Use photos, labels, and visual cues so everyone follows the same process.
• Sustain: Build 5S into your team’s daily routines through audits, team ownership, and visible tracking. Consistency prevents backsliding and keeps the system working over time.

It’s also important to remember to be patient. This can be a long process and can take several iterations to get right, especially if you’re pushing the limits or trying something new. Oftentimes, when things are rushed, it can lead to poor results or mistakes.

5. Standardize Work Instructions and Key Checks

Clear, visual work instructions reduce variation between operators and shifts. Without them, quality depends on memory and individual judgment. That inconsistency shows up in your scrap data and customer complaints.

Include these elements in every work instruction:

• Step order
• Photos or diagrams
• Required tools and settings
• Acceptance criteria

Place instructions at the point of use so operators can reference them without walking away from the station. Add simple check steps at critical moments, such as verifying torque or connector seating, before moving to the next station. These checks catch errors while they’re still easy to fix.

6. Prototype and Pilot With Quality as a Goal

Manufacturing looks-like, works-like, and engineering prototypes let teams expose quality risks before mass production, which helps validate the look and feel. Prototypes reveal how parts fit, how assemblies fail, and where tolerances cause problems. 

To catch potential issues, run the following tests early:

• Drop and impact tests
• Misuse or “abuse” testing
• Environmental cycling (heat, cold, moisture, UV)
• Repeated assembly and disassembly with intended tools

Run a small pilot build on near-final equipment and track scrap, rework, and cycle time for each run. Treat that build like a dress rehearsal and watch how each aspect of the product, along with human use, behaves together. Use what you see to refine the design and update work instructions before full ramp-up so production quality issues show up on pilots, not customer orders.

7. Build a Simple Quality Control Plan for Each Product

Every team should know how to improve quality control in production, starting with a clear plan for each product. That plan should explain what to check, where to check it, and what “pass” looks like. Then, break the work into three simple stages:

• Incoming: Inspect raw materials and components before they enter production. Use simple sampling checks on key dimensions, certifications, and surface quality to catch supplier issues early and avoid building defects into finished goods.
• In-process: Check parts at key stages where defects often start. Focus on critical dimensions, assembly fit, torque, and simple functional tests so operators can spot issues early and stop bad parts from moving forward.
• Final: Verify that completed products meet all specs before packing and shipping. Confirm key functions, compare cosmetics against visual standards, and check labels and packaging so the product arrives ready for customers.

Define sampling rates and clear pass/fail criteria so operators and inspectors know when to stop a batch instead of letting questionable parts move forward.

8. Focus on a Small Set of Quality Metrics

Teams should track only a few key metrics that tie to cost and customer experience. Too many metrics create noise and can slow decision-making. Define quality metrics in plain language so everyone understands what they mean and why they matter, including:

• First pass yield
• Scrap rate
• Rework rate
• Field returns or warranty claims
• Complaint rate for common defects (e.g., sink marks, cosmetic flaws, or functional failures)

Review these metrics weekly with your team. Use trends to guide improvements and celebrate progress when numbers move in the right direction.

9. Train and Involve Your Team in Quality

Training shouldn’t stop after the first week of production. Structured onboarding and refreshers help new and existing operators understand instructions, tools, and quality standards. Regular check-ins and skill updates keep standards consistent as products and processes evolve.

Operators and technicians should feel comfortable flagging problems and suggesting improvements, since they see issues first. They know which stations slow down, which fixtures wear out, and which steps confuse new hires. Leaders should respond quickly and visibly when someone raises a concern so people keep speaking up.

When the team owns quality, they catch problems before they reach final inspection. That ownership comes from training, clear expectations, and a culture where people feel heard.

10. Be Prepared for Unexpected Challenges

Unexpected issues, like tooling problems, material defects, or process drift, are a normal part of manufacturing. Teams need flexibility to adjust workflows, re-prioritize tasks, or reassign resources while they work on fixes. Flexibility should go hand in hand with simple problem-solving so you don’t repeat the same issues every time pressure rises.

Here are some proven strategies for problem-solving when challenges inevitably arise:

• “5 Whys” analysis: Bring the people who saw the defect together and ask “why did this happen” several times. This helps teams move past surface symptoms and uncover the underlying cause, without turning the exercise into a blame game.
• Daily team huddles and maintenance walkdowns: Short, structured floor huddles and operator-led basic maintenance checks make it easier to spot abnormal machine behavior or recurring defects, agree on a quick containment plan, and assign owners to work on the root cause.
• Data-driven root cause checks: Use production and quality data, such as scrap reasons, downtime logs, and inspection results, to see patterns you would miss by memory. A quick review of this data during problem-solving keeps fixes grounded in what’s really happening on the line.

11. Add Technology Where It Simplifies Quality Work

Technology should support production quality — not get in the way. Start with software, sensors, and lab automation that solve a clear problem on the line. When tools fit the workflow, they can speed up decisions, reduce errors, and make each build more consistent. 

The examples below show where targeted technology has the most value in daily quality work:

• Vision systems: Automated inspection cameras catch cosmetic defects and dimensional errors faster than manual checks. They work well for high-volume lines where consistency matters and human fatigue creates risk.
• Real-time data dashboards: Digital displays show live yield, scrap, and downtime so teams can respond quickly when numbers shift. These dashboards turn raw data into action by highlighting problems as they happen.
• Automated measurement tools: Digital calipers, torque sensors, and coordinate measuring machines remove guesswork from critical checks. They provide consistent, traceable data that helps teams understand process drift and validate improvements.

12. Know When to Bring in an Industrial Design and Product Development Partner

Outside help moves the needle when you face chronic cosmetic flaws, assembly problems, or designs that need constant tweaks to run on the line. These patterns signal that internal fixes aren’t enough and a fresh perspective could unlock better results.

• Reviewing current designs for DFM: Poor manufacturability creates quality risk. An industrial design firm can identify where tolerances are too tight, where parts are hard to assemble, or where cosmetic standards don’t match the process capability.
• Planning prototypes and tests: Structured testing validates improvements before scaling up. A product development partner can design test plans, build different types of prototypes, and run pilots that prove changes will work on your production floor.
• Recommending changes: Small design adjustments can eliminate entire categories of defects. Partners with deep manufacturing experience know which changes deliver the biggest quality gains without disrupting timelines or budgets.

Improve Production Quality With StudioRed

Learning how to improve quality in production requires clear standards, aligned teams, and quality built into every stage —from early design to final inspection. The above tips give you a practical roadmap to reduce defects, increase production efficiency, and deliver products that meet customer expectations. When progress stalls or issues repeat, partnering with an experienced product development partner helps move quality efforts forward.

StudioRed has over 40 years of industrial design experience helping companies design products that are easier to manufacture, assemble, and control. Our team knows how to improve quality in manufacturing through DFM reviews, prototype testing, and process-focused design changes that balance cost and performance. 

If you’re facing production challenges or planning a new launch, contact us today to see how we can help build quality into your process from the start.